Temple bar with ball and socket hinge and method of making same

ABSTRACT

A novel hinge assembly for eyeglasses is provided wherein a first structural member for the hinge structure is formed in a first molding step and a second structural member of the hinge structure is formed directly over a portion of the first structural member in a second molding step. The present invention utilizes in-mold-assembly techniques to reduce the assembly steps required to form such a hinge assembly while further resulting in a hinge assembly that has increased adjustability and utility. Specifically, the overmolded components form a ball and socket type joint allowing a large degree of lateral rotation in one direction and a limited amount of freedom in a second direction. This hinge allows the temple portion of the eyeglasses to be folded against the brow bar and the inclination angle between the temples and the brow bar to be adjusted.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is related to and claims priority from earlier filedProvisional patent Application No. 60/576,367, filed Jun. 2, 2004.

BACKGROUND OF THE INVENTION

The present invention relates generally to eyewear assemblies andmethods of manufacturing eyewear assemblies. More specifically, thepresent invention relates to safety eyewear assemblies that aremanufactured utilizing multi-shot molding techniques to achieve uniquemanufacturing and assembly advantages.

In the prior art, there are a large variety of different types ofprotective eyeglasses that are available for protecting a user's eyeswhen engaging in hazardous activities. Generally, however, most of theseprotective eyeglasses are not adapted to be both comfortably worn andadjustable to fit different wearers. Accordingly, wearers have beenforced to wear uncomfortable, poorly fitting protective eyewear,resulting in wearers that disregard proper safety procedures and fail towear protective eyewear.

Several prior attempts have been made to manufacture protectiveeyeglasses that include various degrees of adjustability and the use ofmultiple material types to enhance the wearability of the eyeglasses.For background, reference is generally made to U.S. Pat. No. 5,457,505,issued to Canavan, U.S. patent to Wiedner et al No. 5,890,235, and U.S.patent to Canavan No. 6,196,681 each of which describe a safety eyewearconstruction, the collective specifications of which are incorporatedherein by reference. U.S. Pat. No. 5,457,505, issued to Canavan, forexample, provides one type of adjustable protective eyeglasses that isadjustable to fit various wearers, wherein the temple frame pieces areangularly adjustable about substantially horizontal pivot axes relativeto the lens frame piece and longitudinally adjustable to differentlengths. As can be seen however, when manufacturing this type ofadjustable protective eyeglasses, a large number of separate pieces arerequired to provide the necessary joints and degrees of freedom neededwithin structure of the eyeglasses in order to provide the statedadjustability.

Similarly, U.S. Pat. No. 5,890,235 provides an eyeglass constructionthat provides for adjustable length temple frame pieces and the abilityto angularly adjust the temple frame pieces relative to the brow bar.However, the lens in this construction does not provide for freefloating ends, instead, it is pinned at notches 10 (see FIG. 7).Further, several separate pieces must be molded and subsequentlyassembled thereby increasing the complexity of the assembly process.

U.S. Pat. No. 6,196,681, issued to Canavan discloses a unitary structuremade by a two-shot process in a single mold wherein a hard frame memberis molded to which a secondary soft material is molded and chemicallybonded to form soft contact areas along the inner portion of the browbar and at the nose portions. In this manner, a soft material isprovided to contact the wearer while hard material is provided to engageratchet adjustment pieces as well as a transparent lens structureadapted to cover the eyes of a wearer.

The difficulty with these prior art protective eyeglasses is that eachone is only an incremental improvement and none of them provide acomprehensive solution for manufacturing protective eyeglass that areuniversally adjustable for individual users while also being comfortableto wear and have a reduced number of individual parts to facilitateassembly.

There is therefore a need for a protective eyeglass construction thatfacilitates comfort for the user thereby increasing the likelihood thatthe protective eyeglasses will be worn by the user. Further, there is aneed for a highly adjustable protective eyeglass construction thatallows the eyeglasses to be universally adjustable for all users whilealso having a reduced number of individually formed parts to enhance themanufacturability of the assembly.

BRIEF SUMMARY OF THE INVENTION

In this regard, the present invention provides a novel construction forprotective eyeglasses that includes numerous points of articulationthereby allowing the eyeglasses to be highly adjustable to suit theneeds of virtually all users of the eyeglasses. Further, the presentinvention utilizes complex, multi-step injection molding techniques toform in-mold-assembly (IMA) components that are then incorporated intothe finished eyeglasses thereby reducing complexity and overall assemblysteps.

Briefly, the protective eyewear comprises a brow bar adapted to receiveand support a lens, a noise piece adapted to be snap received into thenose bridge of the lens, and two temple bar assemblies that are snapreceived into the terminal ends of the brow bar. Among the uniquefeatures of the eyewear of the present invention is a centrally anchoredlens which allows the terminal ends of the brow bar to free floatrelative to the lens and to flex outwardly. This ability to flex allowsthe brow to deflect as the temple bar assemblies are moved outwardlyfurther allowing the eyewear to adjust to larger heads.

Additionally, the present invention utilizes novel multi-shot moldingtechniques to provide various hinge connections and telescoping partsthat are all sequentially formed inside the mold cavity during moldingto create IMA subassemblies that do not require any additional assemblysteps once removed from the mold cavity. In the preferred embodimentdisclosed herein, the molding techniques are particularly important inthe formation of adjustable elastomeric nose pads on the nose-piece ofthe inventive eyewear, as well as in the formation of the temple barassemblies that include a ratchet adjustment, hinge, and telescopingcables. Additionally, the multi-shot molding techniques are effectivefor providing soft cushion materials on the inner side of the brow bar,and lens bumpers on the outer side of the brow bar.

Accordingly, it is an object of the present invention to provide safetyeyewear products that are at least partially assembled in-the-mold usingnovel multi-shot molding techniques. It is a further object of thepresent invention to provide safety eyewear having a flexible brow barto accommodate different size heads. It is yet a further object of thepresent invention to provide protective eyewear that includes multiplearticulated joints that increase the overall adjustability of theeyewear to enhance comfort and wearability of the eyeglasses.

Other objects, features and advantages of the invention shall becomeapparent as the description thereof proceeds when considered inconnection with the accompanying illustrative drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings which illustrate the best mode presently contemplatedfor carrying out the present invention:

FIG. 1 is a front perspective view of the safety eyewear of the presentinvention with the lens shown as transparent;

FIG. 2 is a top view thereof illustration temples in normal and flexedpositions;

FIG. 3 is an exploded front perspective view thereof;

FIG. 4 is an exploded rear perspective view thereof;

FIG. 5 is an exploded view of one of the temple bar assemblies;

FIG. 6 is cross sectional view of the brow bar;

FIG. 6A is a cross-sectional view of the brow bar showing an alternativeconstruction having reduced thickness areas beneath the soft elastomericovermolded to provide greater flex of the brow bar;

FIG. 7A is an exploded perspective view of the nose pad assembly;

FIG. 7B is a cross-sectional view of the nose piece showing the nose padand support molded in a two shot molding process;

FIG. 7C is an exploded perspective view of an alternative constructionof the nose pad assembly;

FIGS. 8A and 8B are perspective views of an alternate ball and socketconnection between the temple bar and the brow bar;

FIGS. 9A and 9B are another alternate perspective of a ball and socketconnection between the temple bar and the brow bar;

FIG. 10 is a perspective view of an alternate embodiment of the safetyeyewear having a two part brow bar with snap in sockets on bridge oflens;

FIGS. 11–14 are perspective views of alternate embodiments of the safetyeyewear having a telescoping brow bar configurations;

FIGS. 15–17 are plan views of alternate angular ratchet adjustmentconfigurations that are formed using the in-mold-assembly techniques ofthe present invention;

FIG. 18 is a plan view of an alternate telescoping temple lengthadjustment;

FIG. 18A is a plan view of a second alternate telescoping temple lengthadjustment; and

FIG. 19 is a perspective view of an alternate nose pad configurationthat provides only for rotation of the nose pads.

DETAILED DESCRIPTION OF THE INVENTION

Now referring to the drawings, a preferred embodiment of the safetyeyewear of the instant invention is illustrated and generally indicatedat 10 in FIGS. 1–9. As will hereinafter be more fully described, thesafety eyewear 10 includes a brow bar 12 that is adapted to receive andsupport a lens 14, a nose piece 16 that is adapted to be snap receivedinto the nose bridge of the lens 14, and two temple bar assemblies 18that are snap received into the terminal ends of the brow bar 12.

The invention utilizes novel multi-shot molding techniques to providehinge connections and telescoping parts that are formed inside the moldcavity during molding (In-Mold-Assembly or IMA) and thus do not requireany additional assembly once the part is removed from the mold cavity.In the preferred embodiment disclosed herein, the molding techniques areparticularly important in the formation of adjustable elastomeric nosepads on the nose piece of the eyewear as well as in the integralformation of the temple bar assemblies including a ratchet body, hingebody, and telescoping cables.

Turning to FIG. 1 in combination with FIG. 6, the brow bar 12 is thecentral structural element of the eyewear assembly 10. The brow bar 12is formed using a two shot molding process wherein a hard portion 20 isfirst molded to provide rigidity and strength and thereafter a softelastomeric portion 22 is molded over and bonded to the hard portion 20to provide a soft cushion on the inside surface of the brow bar 12. Thesoft elastomeric material also wraps around the front surface of thebrow bar 12 in selected locations to form soft bumpers 24 between theinner surface of the lens and the outer surface of the brow bar 12,thereby cushioning the brow bar 12 as it flexes forward and preventing arattling sound as it contacts the lens 14. In addition to wrappingaround the brow bar 12, through holes (not shown) may be providedthrough the brow bar to allow the elastomeric material to flow throughthe brow bar 12 as a means to assist in forming the soft bumpers 24 onthe face of the brow bar 12 and to provide additional means forretaining the soft bumpers 24 on the brow bar 12.

Turning now to FIGS. 1–5, one of the unique features of the safetyeyewear 10 of the present invention is the ability of the brow bar 12 toflex outwardly (see arrows 26 in FIGS. 1 and 2) thereby allowing theeyewear 10 to adapt to different brow width of the wearer. Thefunctionality of this feature is further enhanced by the manner in whichthe brow bar 12 receives and retains the lens 14. The lens 14 comprisesa single piece lens shield having left and right lens portionsintegrally connected by a nose bridge, which is secured to the brow bar12 by two spaced detents 28 located on the top edge of the lens 14. Thedetents 28 are received into corresponding notches 30 on the frontsurface of the brow bar 12. Similarly, the detents 28 may also be formedon the brow bar 12 and the notches 30 may be formed on the lens 14wherein the detents 28 are received into corresponding notches 30 formedin the back surface of the lens 14. A channel arm 32 extends forwardfrom the brow bar 12 and downwardly over the front surface of the lens14 to capture the lens 14 against the front surface of the brow bar 12thereby retaining the lens 14 in assembled relation with the brow bar14. This center anchoring arrangement allows the outer ends of the lens14 to float relative to the outer ends of the brow bar 12. While thegeneral concept of a centrally anchored lens 14 is not entirely new, itis noted that the brow bar 12 of the present invention is preferablymolded from a plastic material that is sufficiently flexible so as tomovable through at least a range of motion as illustrated in FIG. 2.Specifically, the brow bar 12 is sufficiently flexible to allow thetemples 18 to be flexed from a static width W to a stretched width of W′allowing the eyeglasses 10 to accommodate a large range of wearers.While some of the prior art shows central anchoring of a lens forsunglasses, the brow bar and frame of these prior art sunglasses aregenerally stiff, and while allowing some degree of flexibility, do notallow the broad range of motion as illustrated in FIG. 2. Morespecifically, the materials selected for the present invention permit arange of motion of the temple bar of about 40–50 degrees measured fromthe anchor point 33 on the lens 14 as illustrated in FIG. 2.

As can best be seen in FIG. 2, when the eyewear is worn by a person witha large head, the terminal ends of the brow bar 12 can freely flexoutwardly from W to W′ as indicated by arrows 26 allowing the eyewear 10to adapt to the proper size. To provide clearance to facilitate theoutward flex of the brow bar 12, the upper edges of the left and rightlens portions are provided with channels 34 or nests into which the browbar 12 is guided during outward flexing. In addition to providing acushioning effect, the soft bumpers 24 extend around on the front of thebrow bar 12 also serve to prevent the brow bar 12 from fully deflectinginto the nests 34 at the top of the lens 14. In this manner, the bumpers24 act a s stand-offs maintaining the brow bar 12 in a slightly spacedrelation to the wall of the nests 34 allowing free airflow out the topof the lens 14 and allowing continued venting even when the brow bar 12ins in a fully flexed position.

To further enhance the ability of the brow bar 12 to flex outwardly, analternate embodiment brow bar 12A is shown in FIG. 6A wherein the browbar 12A includes periodic weakened or narrowed regions 23 in the hardplastic material that facilitate deflection of the brow bar 12A. Theseweakened regions 24 may be arranges such that the elastomeric wraparound material 24 covers and conceals the weakened regions 23 whilefilling them with a softer more flexible elastomeric material.

The novel nose piece 16 of the present invention comprises a v-shapedrigid support portion 36 and two nose pads 38. The rigid support 36 isformed with a groove 40 that mates with the corresponding peripheraledges of the nose bridge on the lens 14 so that the nose piece support16 is snap received onto the lens 14. The nose pads 38 are connected tothe support by a unique ball and socket arrangement that allows 360degree freedom of movement of the nose pad 38 relative to the support 36as well as rotational movement of the nose pad 38. This greatly enhancedrange of motion is an improvement in the present invention over theprior art and facilitates a nose piece that has increased comfort andadjustability for the wearer of the eyewear 10. While the ball andsocket joint provides an enhanced range of adjustment, it is equallyimportant to understand that the ball and socket joint must have someminimal level of friction as well so that the nose pad 38, once adjustedto a desired position, remains in the desired position. In the preferredembodiment as depicted in FIGS. 7A and 7B, the rigid support portion 36is first molded to include the ball portion 42 of the ball and socketjoint. Thereafter, the nose pad 38 is molded over the ball 42 to formthe uniquely adjustable ball and socket assembly. This molding processcould be completed as part of an insert molding process, or as preferredfor the present invention, the molding process is completed within thesame mold using retractable mold sections to mold the nose pad 38directly over the ball element 42 without removing the support 36 fromthe mold, and thus create an assembled part directly within the mold. Asdescribed above, since the ball and socket joint must have some minimallevel of friction between the parts, the molding process and theselection of materials becomes important to creating a functional part.In an alternative embodiment, the ball and socket formations can bereversed, with the nose pad 38 first being formed with the ball 42 andthe support 36 being molded over the ball 42 on the nose pad 38.Further, in the context of using an insert molding technique, it ispossible that the ball element 42 be comprised of a metal material andinsert molded within the rigid plastic support 36. The plastic nose pads38 could then be molded over the metal ball elements 42. Further still,the entire rigid nose support 16 could be constructed from metal and theplastic nose pads 38 molded over the ball elements 42. Additionally,while the rigid support portion 36 may be made from a hard polymer andthe nose pads 38 may be made from an elastomer, the present inventionalso provides for both members to be formed of hard polymer orelastomer. An alternate embodiment as depicted in FIGS. 13, 17 and 19further provides that the nose piece 16 snap into a central portion ofthe eyeglass frame rather than be received by the lens. Still further,it is possible that the nose pads 38 could be molded separately and thenassembled by pushing them onto the ball 42.

Other constructions of the ball and socket joint for the nose pad 38 arealso contemplated. For example, FIG. 7C illustrates that the nosesupport 16 and the ball element 42 of the joint could be integrallymolded as part of the lens 14, and the nose pads 38 could be molded overthe ball elements 42. It is also possible to form a ball and socketjoint by forming a plastic ball element, and slotting the ball elementto provide relief slots. The slotted ball element could then be pressfit into a cylindrical bore of slightly smaller dimensions formed withinthe nose pad 38. The slotted ball would be compressed providing afriction fit within the bore, retaining the ball in place and providingthe required friction to allow adjustment but also retain the nose pad38 in position once moved to the desired position. In yet otherembodiments, the ball would not be slotted, but would be retained withinthe bore by an insert or a rod extending perpendicular to the bore.

Even further still, it is alternately contemplated that the nose pad 38could be formed with a metallic insert at the upper end thereof. Forexample, a U-shaped metallic insert plate with two relief aperturescould be insert molded within the nose pad 38. The ball element is thenpress fit between the plates and received in seated relation between thetwo relief apertures. In yet another construction, a metal ring could bemolded into the nose pad 38 and the ball pressed through the ring forretention. While numerous different constructions have been describedherein, these descriptions are not intended to limit the possibility ofother ball and socket type constructions. The general inventive conceptto be conveyed is that the ball and socket type joint provided betweenthe nose pad 38 and the supporting structure 16 of the nose pad 38provides a superior range of motion, adjustability and comfort notobtained with prior art constructions.

Turning back to FIGS. 1–3 in combination with FIG. 5, the temple barassemblies 18 include three separate elements, namely a ratchet body 44,a hinge body 46 and a cable portion 48. The temple bar assemblies 18 areconfigured so as to provide both an angular ratchet adjustment foradjusting the angle of inclination of the temple bars 18 relative to thebrow bar 12 as well as a hinge for folding the temple bars 18 flatrelative to the brow bar. In addition, the cable portion 48 of thetemple bar assemblies 18 is adapted for telescoping adjustment relativeto the hinge body 46. Generally speaking, the physical construction ofthe three part temple assemblies 18 is within the prior art. Forexample, an almost identical structure is illustrated in the U.S. Pat.No. 5,457,505 discussed hereinabove. In this prior art construction, thethree components were molded separately and then assembled together toform a temple bar assembly. More specifically, the hinge connection hadto be aligned and a hinge pin inserted to form the hinge point.Additionally, the cable had to be pressed onto the end of the templebody.

For purposes of the present invention, the novelty resides in a uniquemethod of construction the temple bar assembly 18 as a single integratedunit which is formed and assembled directly within the mold. In thisregard, the three-part temple bar assembly 18 is formed using a novelthree shot molding process wherein the ratchet body 44 is first moldedfrom first rigid plastic material. The ratchet body 44 includes aratchet formation 50 at the front end thereof and a hinge pin forming avertical pivot axis 52 at the rear end. In a second shot of the moldingprocess, the hinge body 46 is integrally molded (from a slightlydifferent plastic material) over the rear end of the ratchet body 44wherein the hinge eye 54 is integrally formed over the hinge pin withinthe mold. The rear end of the hinge body 46 is provided with anelongated neck 56 that will become part of the telescoping cablestructure. Finally, in a third step, a third (softer)elastomeric/plastic material is injected over the neck 56 to form thesoft curved cable portion 48 of the temple bar. While in the preferredembodiment a soft elastomeric cable portion 48 is disclosed, clearly thecable portion 48 may also be formed from a hard polymer. To provideselected positioning of the cable 48 relative to the neck 56, the neckis provided with a detent 58, and the cable is provided with a series ofpositioning apertures 60. Alternately, the positioning aperture 60 maybe a single elongated aperture. Similarly, in FIG. 18, another alternatecable 90 positioning aperture 88 is shown. FIG. 18A shows yet anotheralternate cable 90 positioning arrangement wherein instead of providinga single aperture, a plurality of apertures 61 are provided to allow thedetent 58 to positively engage in one of the selected apertures 61.Because of the differences in the plastic materials used in the moldingprocess, when the temple bar assembly 18 is removed from the mold, thehinge body 46 is pivotable with respect to the ratchet body 44, and thecable portion 48 is slidably movable relative to the neck 56 of thehinge body 46. No assembly is required once removed from the mold. Toinsure the proper operation and the required movement of each of theelements relative to one another after the molding process is completed,upon removal from the mold each of the joints of the temple bar 18 maybe articulated to prevent the different polymers from bonding to oneanother.

The temple bar assemblies 18 are then assembled with the brow bar 12 bysnapping the respective ratchet body 44 of the left and right temple barassemblies into mating slots 62 on the terminal ends of the brow bar 12.The ratchet body 44 includes a pivot post 64 received in a pivotaperture 66 to form a pivot point similar to those ratchet assembliesfound in the '681 and '235 patents referenced hereinabove. Alternateconfigurations of the ratchet body 44 and formations 50 can be found inFIGS. 15, 16 and 17. It is important to note that the functionalelements of the ratchet body 44 may be formed in a position either aheadof the hinge pivot 52 positioned between the brow bar 12 and the hingepivot 52 or in a position behind the hinge pivot 52 between the reducedneck 56 and the hinge pivot 52. This flexible placement of the ratchetbody 44 allows flexibility in design as well as facilitating the abilityto also form the entire ratchet assembly (body 44 and ratchet receiver62) utilizing IMA techniques and methodology.

Referring to FIGS. 8 and 9, further disclosed embodiments of theinvention include a novel brow bar 12A and temple bar assembly 18A thatis molded in a two shot process with a ball 68 and socket 70 connectionrather than a ratchet and hinge. In the embodiment shown in FIGS. 8A and8B, the temple bar neck and rear portion 73 are preferably molded in afirst molding step wherein the front end of the rear portion 73 includesa ball formation 68. Thereafter, the front portion 71 is molded over theball 68 to form a socket formation 70 surrounding the ball 68. Thefacing surfaces of the temple bar 18A and brow bar 12A are curved onselected surface to allow relative rotation and movement, and inaddition, the front portion 71 is provided with a slot 74 on the innerside thereof to permit a hinge/pivot movement of the temple bar 18Asimilar to a conventional hinge. The particular arrangement as shownincludes a curved side surface 73 a on the rear portion 73 which permitspivoting movement along a vertical axis. It should be noted that theupper and lower surfaces at the front edges of the rear portion are alsosomewhat rounded to generally permit pivoting of the rear portion as atrue ball and socket joint. This two shot process would eliminate theseparate formation of the hinge body and would thus reduce cost andsimplify manufacture. Similarly, as disclosed above, the cable ends 48may be molded over the temple bar 18 to form telescoping templeadjustment. The reverse arrangement of the ball and socket joint isshown in FIGS. 9A and 9B wherein the ball formation 68 is formed on thefront portion 71 and the rear portion 73 is molded the ball 68 to createa socket 70.

Referring to FIG. 10, a second alternate embodiment brow bar 12 c isshown wherein the brow bar 12 c is made in two pieces. The lens 14 isformed to include a receiver channel 32 c along the top edge thereofwherein the receiver channel 32 c includes openings 32 d in its endsthat are configured and arranged to receive and frictionally retain theterminal ends 12 d of the two brow bar segments 12 c.

In another alternate embodiment as depicted in FIG. 11, the brow bar 12e is formed as a continuous member and the lens 14 a is formed as a twopiece lens. The two lenses 14 a are centrally supported along thecentral portion of the brow bar 12 e by any known support means such asthe support clip 32 d shown. The terminal ends 14 b are free floatingand not restrained or connected to the brow bar 12 e thereby allowingthe free flexing of the brow bar 12 e in accordance with the teachingsof the present invention. Additionally, the lenses 14 a may includenests 34 along their top edges to allow room for the flexing of the browbar 12 e or may simply stop short at a point beneath the brow bar 12 e.

Turning now to FIGS. 12–14, several additional embodiments are disclosedwherein the brow bar 12B telescopingly adjusts for length. In thisregard, a central bridge portion 74 of the brow bar 12B includes leftand right temple extensions 76. Each temple extension 76 includesnotches or slots 78 for receiving a mating pin formation 80 provided ona mating temple extension 82 of the temple bar assemblies 18. It isnoted that the temple bar assemblies 18 in this embodiment are formed ina four part molding processes wherein the mating temple extension 82 isformed first having a hinge pin 84 formed at the rear end, followed by ahinge body 86, the temple bar 88 as depicted in the detail in FIG. 6includes a ratchet formation at the front end, and a telescoping cableend 90.

It can therefore be seen that the present invention discloses a noveland creative use of multi-shot molding techniques to provide integrallymolded yet movable parts, as well as to provide both decorative andfunctional cushioned areas. For these reasons, the instant invention isbelieved to represent a significant advancement in the art that hassubstantial commercial merit.

1. A temple bar assembly including a front portion and a rear portion,said front portion and said rear portion being movably coupled by a balland socket joint including a ball formation and a socket formation, saidtemple bar assembly being formed by an in-mold-assemblyinjection-molding process comprising the steps of: injection moldingsaid front portion with said ball formations, said front portion beingmolded from a first plastic material; molding said rear portion formingsaid socket formation around said ball formation, said rear portionbeing formed from a second plastic material wherein said rear portion isassembled with said front portion but movable relative to said ballformation.
 2. The temple bar assembly of claim 1, wherein said frontportion and said rear portion are molded within the same molding tool.3. The temple bar assembly of claim 1, wherein said front portion ismolded in one mold tool and then inserted into a second mold tool formolding of the rear portion.
 4. A temple bar assembly including a frontportion and a rear portion, said front portion and said rear portionbeing movably coupled by a ball and socket joint including a ballformation and a socket formation, said temple bar assembly being formedby an in-mold-assembly injection-molding process comprising the stepsof: injection molding said rear portion with said ball formations, saidrear portion being molded from a first plastic material; molding saidfront portion forming said socket formation around said ball formation,said front portion being formed from a second plastic material whereinsaid front portion is assembled with said rear portion but movablerelative to said ball formation.
 5. The temple bar assembly of claim 4,wherein said front portion and said rear portion are molded within thesame molding tool.
 6. The temple bar assembly of claim 4, wherein saidrear portion is molded in one mold tool and then inserted into a secondmold tool for molding of the front portion.
 7. Eyeglasses including aframe and at least one temple bar assembly extending rearwardly from aside edge of said frame, said temple bar assembly having a front portionconnected to said frame, and further having a rear portion, said frontand rear portions of said temple bar assembly being movably coupled by aball and socket joint including a ball formation and a socket formation,said temple bar assembly being formed by an in-mold-assemblyinjection-molding process comprising the steps of: injection moldingsaid front portion with said ball formations, said front portion beingmolded from a first plastic material; molding said rear portion aroundsaid ball formation, said rear portion being formed from a secondplastic material wherein said rear portion is assembled with said frontportion but movable relative to said ball formation.
 8. The eyeglassesof claim 7, wherein said front portion and said rear portion are moldedwithin the same molding tool.
 9. The eyeglasses of claim 7, wherein saidfront portion is molded in one mold tool and then inserted into a secondmold tool for molding of the rear portion.
 10. Eyeglasses including aframe and at least one temple bar assembly extending rearwardly from aside edge of said frame, said temple bar assembly having a front portionconnected to said frame, and further having a rear portion, said frontand rear portions of said temple bar assembly being movably coupled by aball and socket joint including a ball formation and a socket formation,said temple bar assembly being formed by an in-mold-assemblyinjection-molding process comprising the steps of: injection moldingsaid rear portion with said ball formations, said rear portion beingmolded from a first plastic material; molding said front portion aroundsaid ball formation, said front portion being formed from a secondplastic material wherein said front portion is assembled with said rearportion but movable relative to said ball formation.
 11. The eyeglassesof claim 10, wherein said front portion and said rear portion are moldedwithin the same molding tool.
 12. The eyeglasses of claim 10, whereinsaid rear portion is molded in one mold tool and then inserted into asecond mold tool for molding of the front portion.
 13. A hinge assemblyfor eyeglasses comprising: a brow bar having at least a first end, saidfirst end configured as a ball portion of a ball and socket type joint;and at least one temple member having a first end and a second endopposite said first end, said first end being formed in engaged relationwith said ball portion of said brow bar wherein said first end of saidtemple member forms a socket portion of a ball and socket type joint,wherein said temple member is pivotable around a vertical axis relativeto said brow bar, wherein said hinge assembly is formed in a multipleshot molding process wherein said brow bar is formed in a first moldingstep and the temple member is formed in a second molding step by formingsaid first end of said temple member in engagement with said ballportion of said brow bar, said hinge assembly being completed uponremoval from the mold.
 14. The hinge assembly of claim 13, furthercomprising: a lens assembly attached to said brow bar, wherein saidtemple member is pivotable about a horizontal axis relative to said browbar and lens assembly, wherein the angle of inclination between saidtemple bar and said lens assembly can be adjusted.
 15. The hingeassembly of claim 13, said brow bar having a first end and a second endopposite said first end, each of said first and second ends configuredas a ball portion of a ball and socket type joint; and a first andsecond temple member each having a first end and a second end oppositesaid first end, said first end of said first temple member being formedin engaged relation with said ball portion of said first end of saidbrow bar, said first end of said second temple member being formed inengaged relation with said ball portion of said second end of said browbar, wherein said first ends of said first and second temple membersform a socket portion of a ball and socket type joint, wherein saidfirst and second temple members are pivotable relative to said brow bararound first and second vertical axis respectively.
 16. The hingeassembly of claim 15, further comprising: a lens assembly attached tosaid brow bar between said first and second ends of said brow bar,wherein said first and second temple members are pivotable about ahorizontal axis relative to said brow bar and lens assembly, wherein theangle of inclination between said first and second temple bars and saidlens assembly can be adjusted.
 17. A method of manufacturing a hingeassembly for eyeglasses comprising the steps of: providing a mold cavityhaving a first profile; filling said mold cavity with a first polymer toform a brow bar having a first end and a second end opposite said firstend, at least said first end being configured as a ball portion of aball and socket type joint; removing a first portion of said moldcavity, said portion being adjacent said first end of said brow bar;replacing said removed first portion of said mold cavity with a secondmold cavity having a second profile; and filling said second mold cavitywith a second polymer to form at least one temple member having a firstend, said first end being formed in engaged relation with said ballportion on said first end of said brow bar, wherein said first end ofsaid temple member forms a socket portion of a ball and socket typejoint, said temple member being pivotable around a vertical axisrelative to said brow bar, wherein said hinge assembly is a completedassembly upon removal from the mold cavity.
 18. The method of forming ahinge assembly of claim 17, further comprising the steps of: removingsaid completed assembly from said mold cavity; and articulating saidtemple member relative to said brow bar to ensure that said templemember and said brow bar are not bonded to one another.
 19. The methodof forming a hinge assembly of claim 17, said brow bar having a firstend and a second end opposite said first end, each of said first andsecond ends configured as a ball portion of a ball and socket typejoint; and said step of forming at least one temple member comprisesforming a first and second temple member each having a first end and asecond end opposite said first end, said first end of said first templemember being formed in engaged relation with said ball portion of saidfirst end of said brow bar, said first end of said second temple memberbeing formed in engaged relation with said ball portion of said secondend of said brow bar, wherein said first ends of said first and secondtemple members form a socket portion of a ball and socket type joint,wherein said first and second temple members are pivotable relative tosaid brow bar around first and second vertical axis respectively.
 20. Amethod of manufacturing a hinge assembly for eyeglasses comprising thesteps of: providing a mold cavity having a first profile; filling saidmold cavity with a first polymer to form at least one temple memberhaving a first end, said first end being configured as a ball portion ofa ball and socket type joint; removing a first portion of said moldcavity, said portion being adjacent said first end of said templemember; replacing said removed first portion of said mold cavity with asecond mold cavity having a second profile; and filling said second moldcavity with a second polymer to form a brow bar member having a firstend and a second end, at least said first end being formed in engagedrelation with said ball portion on said first end of said temple member,wherein said first end of said brow bar forming a socket portion of aball and socket type joint, said temple member being pivotable around avertical axis relative to said brow bar, wherein said hinge assembly isa completed assembly upon removal from the mold cavity.
 21. The methodof forming a hinge assembly of claim 20, further comprising the stepsof: removing said completed assembly from said mold cavity; andarticulating said temple member relative to said brow bar to ensure thatsaid temple member and said brow bar are not bonded to one another. 22.The method of forming a hinge assembly of claim 20, wherein said step offorming at least one temple member comprises forming a first and secondtemple member each having a first end and a second end opposite saidfirst end, said brow bar having a first end and a second end oppositesaid first end, said first end of said brow bar being formed in engagedrelation with said ball portion of said first end of said first templemember, said second end of said brow bar being formed in engagedrelation with said ball portion of said first end of said second templemember, wherein said first and second ends of said brow bar form asocket portion of a ball and socket type joint, wherein said first andsecond temple members are pivotable relative to said brow bar aroundfirst and second vertical axis respectively.